health & safety seminar · sop format, to include: permitted access routes to the roof and...
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HEALTH & SAFETY
SEMINAR
SLIPS CASE STUDYDave Penson
Safety, Health, Environment, Energy Manager
Young’s Seafood
HEALTH & SAFETY SEMINAR
Health & Safety Cultural Change
We’re the Nation’s Favourite Seafood Brand
No.1
ScampiBattered
Ready Meals
Fish in Sauce
Fish Cakes
Breaded
brand in frozen
No.1in foodservice
brand in chilledNo.1
The UK’s Leading Seafood Company
Fraserburgh
Livingston
Annan
Kilkeel
Grimsby
• Over 200 years’ experience in
producing responsibly sourced seafood
• Number 1 in both frozen and chilled
fish in the UK
• Produce 1 in 3 of the 2 billion fish
meals enjoyed by UK consumers every
year
• Uniquely positioned spanning brand,
retailer brand, frozen, chilled and
foodservice
• UK turnover of £500m
• 3,000 people across 7 UK sites
What’s in it for you?
• Reduction in claims cost
• Reduction in lost time accidents
• Reduction in claims
• Improved quality of risk assessments (employee engagement)
• Increased profitability (through lost time improvement)
Reduced RIDDOR reportable accidents at target site 2005 reported 20 cases . In 2017 ZERO .
Claims defence 50% improvement (Good documentation)
0
5
10
15
20
25
05 06 07 08 09 10 11 12 13 14 15 16 17
No
Of
case
s
Year
R IDDOR R EPORTABLE
0
20
40
60
80
100
05 06 07 08 09 10 11 12 13 14 15 16 17N
o o
f C
ases
year
Lost Time Accidents -Group
What’s in it for you?
What did we do?
• We delivered Safety seminar – All managers & people involved in an accident
• We delivered Risk assessment training 4 hrs in house
• We delivered Incident investigation training 4 hrs in house.
• Solicitor Engagement , close out advice .
• Secured Key commitment – Root Cause Analysis team – Site MD presence
• Set Key Performance indicators across the group No of LTA V RCA carried out.
• Claims cost is a Key Performance indicator at all sites , cost & No accidents
Disease
Reflecting on historic process
• High levels of HSE reportable accidents .
• No stepped change in last 10yrs plus
• Common practice to hand out 1st stage warnings ( Take more Care)
• Safety meetings poor attendance
• Senior management engagement low
Monthly operations meeting - It was reported that site figures where going in the right direction and we should be pleased . In fact we where not as we did not understand what drove the stats LUCK ? .
RISK ASSESSMENT TRAINING
Health and safety at work act 1974
It shall be the duty of every employer to ensure, so far as is reasonably practicable,
the health, safety and welfare at work of all his/her employees.
Regulation 3 of the Management of Health And Safety at Work Regulations
states that “every employer shall make a suitable and sufficient assessment”.
■ Its about daily management of your work area
■ Having an open culture of risk so your team can come to you if they feel there is a potential
risk in the area
■ Leading by example
■ Being alert and aware of potential risks in your area
■ Stopping something before it escalates
■ Stopping bad behaviour
■ Reporting machinery failure / fixtures
■ Providing instructions and training
■ Open culture of good health and safety practices
■ Disciplining where appropriate
■ Carrying out an accurate completion of a risk assessment because you want to
Slide 12
Factors that cause incidents
Unsafe Acts
• Taking guards off machinery
• Not wearing correct PPE
• Climbing over machinery or up racking
• Throwing debris and rubbish on the floor
• Ignoring safe procedures
• ‘Playing’ around in a vehicle control area
• Not reporting unsafe conditions
Unsafe Conditions
• Rubbish on the floor
• Blocked gangways
• Pallets stood on end
• Loads on pallets not secure
• Guards missing from machines
• Boxes overloaded
• Trailing cables
Unsafe People
• Untrained personnel
• Fooling around
• Ill and back at work too soon
• Unconfident to do the task
• Without the correct PPE or tools and
equipment
• Management – role modelling, leading by
example, cutting corners to meet deadlines
Slide 13
Main Types of Incidents
4 types of incidents that we investigate and
record..
Safety Opportunities or Near Misses
Helps us prevent future accidents (HSE research – 189 safety opportunities for
each LTA)
Minor
Accidents requiring minor first aid with the person returning to work following
treatment
Lost Time Accidents (LTA)
Any accident whereby the injured person does not return to work or would not
be capable of work the following day.
HSE Reportable under RIDDOR (Over 7 Days
/ Major / Fatality / Ill Health / Dangerous
Occurrence)
Any accident preventing an employee from carrying out their normal duties for
more than 7 days or a major injury as described in the RIDDOR regulations and
guidance. A dangerous occurrence could for example: Gas release or explosion,
collapse of scaffold or structure, serious failure of lifting equipment etc.
OLD INCIDENT PROCEDURE
Accident occurs
First aid Incident
notificationFLM Accident investigation
Outcome
Treatment given by factory F/A, or sent to hospital,
brief first aid report written
E-mailed by the on shift FLM to
all relevant managers
FLM to investigate accident on their own and publish
findings
Normal outcome lack of due care and attention by
injured party
FLM’S INVESTIGATE IN
ISOLATION
ACCEPTANCE OF OPERATOR ERROR
OUTCOMES
LACK OF INVOLVEMENT FROM OTHER
PARTIES
RCA’s
A Root Cause Analysis (RCA) is a structured process aimed towards understanding the immediate cause or causes of any accident, injury, or incident that has occurred within the workplace
RCA’s follow guiding principles taken from Problem Solving Summary Activities (PSSR) and use the DMAIC flow
The aim is to guide and support injured parties in understanding causes, and helping them take a pro-active role in improving or changing a particular process or area in order to eliminate the risk of re-occurrence
RCA PROCEDURE
Accident occurs First aid Incident notificationFirst Aider
Investigation
Statements & photo’s
Outcome Invite to attend RCA
Hold RCA session review all
documents (Define, Measure, & Analyse)
Review area / equipment check for
faults
Set actions for attendees of RCA
session
Hold 2nd session to review set actions
Devise and implement
improvement themes
Review Improvements to
check sustainability (Improve & Control)
Cross functional team
Rigorous Root Cause
Analysis
Agreed Action Plans to ensure team
commitment
Slide 17
Begin Incident Investigation
Begin incident investigation
The Golden Hour
LL8
Poor Incident Form
Blank Incident Form
P131
FOCUS GROUP
• Group invitations sent via e-mailed calendar alerts
• Cross functional teams to promote discussion and agree best practice
• Group member roles generated at first meeting ensure awareness and commitment
• Mini RCA’s are used for accidents where the employee has returned to work, smaller focus group
• Full scale RCA’s are used for analysing any lost time accidents or for any serious occurrences, senior team involvement
CASE STUDY
Michael F Smith LTA
Root Cause Analysis Closure
Lost Time Accident
Location – SQ Coated factory yard
Date of Accident 13/12/14
Day of the Accident
The IP was accompanying
a contractor from the
factory to the roof void and
the route they took was
through the plant room and
out of the fire exit leading to
the yard, in order to access
the staircase to the roof.
The IP lost his footing on
the sloped exit and slipped,
causing him to land
awkwardly and injure his
knee.
Root Cause Analysis (RCA)
An RCA was carried out by the Senior Team and Steve Lidgett in the presence of the injured party
A variety of potential causes for the slip and poor practice were identified through the problem solving exercise.
Cause and Effect diagram
Cause and Effect
Action Plan
After the RCA, a list of agreed actions was issued to the attendees.
Action Plan – The PPE
The PPE
✓ The Injured person was issued with some new safety footwear
✓ The supplied footwear by Arco was withdrawn due to supply issues around the time of the accident, so new styles were trialled around all areas of site prior to agreement for ongoing supply.
✓ A toolbox talk on safety footwear was devised and issued to all staff individually.
✓ A check of each persons footwear is being made in conjunction with the audiometry testing which is in progress. This will be re-checked at suitable intervals.
Action Plan – Modification to the Area
The following actions are completed or underway:
✓ PIH scrubbed the walkway to remove the algae
✓ Mid handrail and slope edge rail extended for support.
✓ Pipe-work re-routed from side of bund wall
✓ Fire door returned to fire exit route only and the team are committed to upgrading the door security and emergency lighting as part of the ongoing site plan.
✓ New high pressure pipe-work being installed for cleaning. Re routing through crumb room instead of fire door
Action Plan - Procedures
✓ Action Plan
Procedures – Roof Void Access
One of the issues that contributed towards
the accident was the incorrect route towards
the roof void.
We have decided to review and refresh our
roof void safety procedures as initially they
were issued for contractors, however may not
have been issued as clearly to our own
employees.
We hope to rectify and improve this
deficiency by updating the old version to an
SOP format, to include:
▪ Permitted access routes to the roof and
voids.
▪ Restricted zones
▪ Photographs to illustrate the types of hazards
encountered , e.g. light fittings, composite
panel surface
▪ Weight / people limits.
Procedures – Winter gritting.
We had an existing gritting plan, however we
had not been specific about the routes from
fire exit doors. This is updated on the winter
plan and has been aided by the purchase of
additional salt bins which have positioned at
some of the less populated areas. Machine
Minders assist with gritting during routine site
checks.
What we do
News letter
Car draw
JCG
Wellbeing clinic
Healthy work place
Mental health support workers
Cancer champions
OCH
Local senior mangers pledge
2020 vision and targets
Safety seminar
Cycle to work
Safety week ( Full week LTA free 6 months ) E&C over a year
Rolling management trainingRolling operative trainingFree vendRca all accidentsRca LTA with director supportSafety first all meetingsWeekly ops kpisMonthly ops kpisMonthly safety meetingQuarterly senior site review of SHEEmployee survey
Staying Well at work
“Young’s have been massively instrumental in supporting my project “Staying Well in Work which focuses on “early” intervention identifying stress/anxiety issues before they escalate. Its the “primary key” to keeping staff well in work. The employees then feel better…and the natural increase in productivity business wise will be self-evident. It starts with business wanting to help and Young’s do this at all levels. And are now leading the way..”
Mark Silvester
“Staying Well In Work”
Employment Specialist Mental Health Job Retention
Open Minds
Grimsby
HEALTH & SAFETY
SEMINAR
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